Composite System and Method for Pile Construction and Repair

A polymer composite composition for marine repairs comprising:

• a liquid epoxy blend comprising up to 15 wt. % benzyl alcohol and having a viscosity of 220 to 1100 cps;
• a liquid hardener comprising up to 25 wt. % benzyl alcohol and having a viscosity of 30 to 85 cps;
• and wherein the total benzyl alcohol content of the combined resin and hardener ranges from 1 to 12 wt. %;
• and,
• a particulate inorganic filler comprising 10 to 50 wt. % of particles under 150 μm and 50 to 90 wt. % of particles between 150 μm and 1.18 mm.

A grout preparation kit for marine repairs comprising:

• a first package holding a first premeasured quantity of a liquid epoxy blend comprising up to 15% benzyl alcohol and having a viscosity of 200 to 1100 cps;
• a second package holding a second premeasured quantity of a liquid hardener comprising up to 25% benzyl alcohol and having a viscosity of 30 to 85 cps;
• and,
• a third package holding a third premeasured quantity of a dry particulate filler comprising 10 to 50 wt. % of particles under 150 μm and 50 to 90 wt. % of particles between 150 μm and 1.18 mm, wherein:
• the premeasured quantities of the liquid epoxy blend and hardener, when combined, comprise 1 to 12 wt. % benzyl alcohol, and,
• the premeasured quantity of dry particulate filler, when combined with the premeasured quantities of epoxy blend and hardener, produces a flowable grout composition suitable for placement into a pile jacket.

A method for protecting a marine structure comprising the steps of:

• forming a split polymer composite jacket;
• placing the composite jacket around a selected marine structure;
• drawing the composite jacket together and securing the resulting overlap;
• sealing the bottom of the jacket with a curable composition;
• forming an epoxy grout composition comprising:
• a liquid epoxy resin comprising up to 15 wt. % benzyl alcohol and having a viscosity of 220 to 1100 cps;
• a liquid hardener comprising up to 25 wt. % benzyl alcohol and having a viscosity of 30 to 85 cps, and, wherein the total benzyl alcohol content of the combined resin and hardener ranges from 1 to 12 wt. %;
• and,
• a particulate filler comprising 10 to 50 wt. % of particles under 150 μm and 50 to 90 wt. % of particles between 150 μm and 1.18 mm;
• blending the epoxy grout composition and placing it into the annular space between the polymer composite jacket and the marine structure;
• and,
• allowing the epoxy grout composition to cure in place.